Printing of fibrous materials by impregnation



Patented I Jan. 14, 1936 PATENT OFFICE' PRINTING OF FIBROUS MATERIALS BY IMPREGNATION Melvin R. Greiser, Cincinnati, Ohio, assignor to Carthage Mills Incorporated, Carthage, Ohio, a

corporation of Ohio Original application June '7, 1933, Serial No.

Divided and this application March 12, 1935, Serial No. 10,686

8 Claims.

This is a division of my co-pending application, Serial No. 674,723, filed June 7th, 1933, and entitled Printing of fibrous materials by impregnation.

My invention relates to the printing of fibrous materials, pile fabrics and the like. In themanufacture of carpeting and other pile fabrics it has been the general practice to produce designs by weaving the material initially from yarn: or threads of differing colors. It has been realized that fabrics might be more cheaply made were it possible to produce the desired designs in them by a printing process employing dyes, after fabrication. More or less successful attempts have been made to print upon pile fabrics or fibrous materials by mixing dyes and mordants, together with certain materials to give body to the mixture, and then using the mixture in place of ink in a printing process. Difficulties have been met with, however, which in general have to do with the penetration of the color, the fixing of the color upon or into the fibres, adequate printing mechanism in view of the difficulty of handling dye combinations and corrosive mordants, mechanical difliculties in printing, such as the collection of lint by the plates, etc. The primary object of my invention is to provide an adequate, cheap and simple process for printing by impregnation, pile fabrics or fibrous however, that my invention is by no means confined to any particular character of fabric, woven or unwoven, upon which printing is desired. If it is my object, however, to produce the said inexpensive fioor covering, it will be obvious that considerations of economy in process and apparatus become very important. Consequently it is a more specific object of my invention to provide a simplified general process for the purpose desired. It is also my object to provide a process in which, for the printing step, ordinary printing means such as have heretofore been employed in the felt base floor covering art, may be utilized without deterioration. It is also my object to make provision for a better penetration of the color, for the protection of the printing plates and general apparatus, and for taking care of the necessary supplementary operations, such as,

steaming the web. g

These and other objects of my invention which will be set forth hereinafter or will be apparent athe aforesaid exemplary embodiment. Reference is made to the drawing, wherein:

Figure 1 is a semi-diagrammatic view of a printing machine arranged in accordance with my invention to carry out my process.

Fig. 2 is a representation of a web of material treated by my process. Fig. 3 is a, sectional view of a steaming device. As aforesaid, I shall describe my invention in connection with the printing of a relatively inexpensive non-woven, felted mass or pad of fibers. Such materials are now obtainable on the market in wide widths. They are made up of a relatively loosely felted mass of fibers, for the most part animal fibers. One face of the web is usually treated with such a substance as rubber latex, which contributes some strength to the web, and also gives it non-slipping characteristics when used as a rug. While my invention is not limited to any particular material to be printed upon, the material referred to is relatively inexpensive and is suitable for the manufacture of rugs which are both durable and beautiful, and which are exceedingly economical providing the problems connected with the treating of the same are solved. Hitherto such problems have been baffling. An attempt has been made to mix a mordant, such as formic acid, with suitable dyes and gums to give body to the composition, and then print therewith upon the web. But inadequate penetration has been secured, the printing plates soon pickup lint or dust from the web and become fouled so that the printing is no longer cleanly done; and the acid mordants are corrosive in their character and attack the printing plates if they are of metal, and in any event attack the machinery bearing the printing plates. The steaming has had to be done in large chambers or ovens, and where intermediate steamings are necessary the process has had to be interrupted. Attempts have been made to steam the web by blowing live steam thereon from a plurality of nozzles; but this is both wasteful of steam and creates unpleasant working conditions. Additionally, unless the steam is specially produced, it is likely to contain oil or grease and foreign materials, which tend to soil the web. The admission of live steam to steaming chambers is subject to the same disadvantages, though to somewhat lesser degree. In addition, washings and dryings of the web, where necessary, have greatly slowed up the process; and these factors have in general made the printing of webs of the character described an operation out of all proportion as to costliness to the cost of the web itself.

I have found that by my process, webs of the character described, or pile fabrics, etc. may be adequately printed upon the ordinary fiat bed printing press used in the manufacture of felt base floor coverings. It should be understood that my invention is lot limited to use upon flat bed printing presses, but that the principles may be applied and practiced upon other types of printing machinery, such as the rotary presses and the like; and I desire the appended claims to be understood as not limited to the general features of any particular character of printing mechanism, excepting where specifically set forth.

I have found that by the application of the mordant and penetrant or wetting agent first to the web, I secure a number of remarkable advantages. In the first place, the mordant handling equipment is localized at one point and is reduced to a minimum. Within the limits of sound economy it can be such equipment as is not affected by the corrosive character of the mordant, or if not, can be replaced from time to time, as necessary, without great cost. Secondly, the remainder of the printing machine, including the printing plates and moving parts are protected from the action of the mordant and do not tend to be corroded thereby. In the third place, the wetter character of the web, I have found, entirely prevents the printing plates from picking up and becoming fouled by dust, lint, fibers and etc. from the web. In the fourth place, when the web is wetted without being entirely saturated by the mordant, the penetration of colors into the web is much more effective, The dye substance employed appears to strike downwardly through the web, penetrating substantially throughout its depth without undesirable side spreading of the color. In the fifth place, my printing mechanism handles nothing but the dye substance, together with such gums or other materials as may be thought necessary to give the dye sufiicient body. This appears not only to give me a more advantageous substance for color application, but also appears to make for greater permanence in the web. In the sixth place, the character of operations performed by me are exceedingly simple, and where desired, may be repeated as often as necessary. Thus the web may be mordanted and printed, and afterward mordanted again. Printings may follow mordantings as often as desired, and double printings may be employed.

Again I have devised a method and means for steaming the web. In general these means are analogous to the printing means in that they contact the sheet or web intermittently, as in the fiat bed press, or by a rolling contact as in the rotary press. They are in the nature of pressing and steaming devices in which the steam escapes to the web through confining means which not only permit steaming at a higher temperature, but localize the action of the steam and filter out of the steam such foreign substances as might otherwise stain or soil the web.

I have illustrated my invention in Fig. l as applied to a fiat bed printing press of the type generally used for the paint printing of felt base fioor coverings. The press is an elongated structure built upon a frame I, having a table 2. The sheet 3 is carried over this table from a source of supply 4, by means of the ordinary chain carrying device having points to penetrate the web, or otherwise as desired. Upon the framework there are mounted a series of reciprocating standard devices 5, controlled by cams 6. The standards 5 bear the printing blocks or plates 1. As the cams 6 rotate in timed relationship, the standards 5 are caused to pull the plates 1 down into contact with the web during periods of rest thereof, and to raise them out of contact with the plate during the inking operation, and during the movement of the web. The web of course moves in a step by step manner through the printing device. Inking pans 8 to contain the color are provided. These pans contain suitable application devices, not shown, but usually in the nature of rolls with doctors, and they are mounted to reciprocate longitudinally of the machine. For this purpose small wheels on the pans engage tracks along the edges of the machine, and mechanism is provided to move the pans in synchronism with the other movements of the machine so that when the printing plates are raised, the pans pass beneath them and apply color to the printing surfaces, all as is understood in this art.

An exemplary printing machine of this character contains 30 or more of the standards 5, which will be found adequate for the carrying on of my invention.

I have shown a web 3 coming from a supply roll onto the table 2. As an initial operation I apply the mordant to the web. For this purpose I have shown a series of nozzles 9. located above the table from which the mordant is sprayed onto the web. I prefer this method of application because it is one of the simplest and least expensive which I may use, but other methods of application are suitable. I may apply the mordant by means of felt-covered blocks, or by means of a roll, which may be of rubber or other acid resistant substance. Under some circumstances I can knife the mordant onto the web; but I do not ordinarily prefer to do this, since while I desire my web to be thoroughly wetted, I.do not desire it to be completely saturated. Consequently spray coating or roll coating is preferable, in my opinion, either to knifing or to passing the web bodily beneath the surface of a bath of mordant, which, however, might be done.

Next it is usually advantageous to steam the web after mordanting to soften the fibers and increase the penetration thereof by mordanting. I have shown two of the standards marked 5a, as bearing steaming devices indicated generally at l0. These devices have connections II, with a source of live steam which may, of course, be either the general steam supply of the plant or a special source. Steaming devices will in general be more or less of the same proportions as the printing plates with reference to their area, but it is obvious that they may be larger or small er, as desired, and more particularly that more than an oppositely disposed pair of standard members 5a may be employed to control a single steaming device.

I have illustrated in Fig. 3 a sectional view of an exemplary steaming device. It comprises a top member l2, having passageways I! for steam and having the connection I I. Beneath the head I usually prefer to provide pads of fibrous material indicated at H. These give resiliency to the steaming device, and also act as filters to remove from the steam foreign materials therein; A general, pervious covering I5 is provided to cover the under surface of the steaming device.

I have shown at l6 diagrammatically a two-way valve which may be understood as either manually controlled or controlled in synchronism with the operation of the printing machine by a suitable cam arrangement. This valve is connected by means I! to a source of steam, and by means l8 either to a vacuum pump, or to a source of air under pressure. When the valve mechanism is moved to the left, steam is admitted to the steaming device. When it is moved to the right, the steam is cut off and connection is made to the vacuum pump or source of air. Vacuum is preferable because it tends more effectively to remove the steam. When the valve is in neutral position no fluid pressure is applied to the steaming device. The general sequence of operations will be. a lowering of the steaming device against the web under pressure, the application of steam thereto for a predetermined interval, the cutting off of the steam-and the application of vacuum thereto, and finally the raising of the steaming head.

Having thus beensteamed'; the web 3 passes beneath the printing heads I on the standards 5 \and is printed in much the same manner as the printing operations heretofore carried on on felt base floor coverings. The pans contain suitable dyes, together with body-giving gums. The previous application of mordant to the web increases the penetrative power of thedyes so applied. The pre-treatment of the fibers with the mordant increases the fastness of the colors produced, whereas the previous steaming of the web also appears to assist the penetration of the fibers by the dyes.

In some instances double printing operations will be found desirable. Thus a plurality of the printing plates 1 may be employed to print one color,'or the cam arrangement which controls the travel of the web maybe so adjusted that two or more printing operations by the same plate are performed upon the same portion of the web.

Intermediate the printing operations if desired, another mordant application may be made as by means of the nozzles 9a, and the web may again be steamed by heads Illa.

Additional printings may be carried on as by blocks la, and a final steaming applied, as by heads lllb.

It should be pointed out that the nature of the steaming devices employed by me permits a much more eifective steaming of the web. By reason of the close contactof the steaming device to the web, not only may the steaming be carried on under considerable pressure, but also for that reason at an elevated temperature. The purposeof the gum in the dye, as aforesaid, is

to give it suitable body for printing. An excess of gum or poorly distributed gum is not desirable in the web. If a printed web is treated with steam merely by blowing the steam upon it, there is a tendency of the gum to segregate toward the top of the sheet, giving an undesirable surface texture. On the contrary, in my process there is a tendency for the gum and wetting agent to penetrate the web and, so far as it segregates, to segregate at or near the bottom of the web, where it increases the permanency of the web, leaving the upper dyed fibers clear and brilliant.

Since my printing plates do not have to carry mordant, I may, if desired, use metal printing plates, though wooden plates are in general preferable and more economical. In any event, the machinery is protected from the mordant, and the plates show no tendency to pick up lint and foreign matter.

After a final steaming, the web may either be finished, or if a washing is desired, it may be carried through a washing pan l9 and finally steamed to dry it by one or more steaming heads lllc, on standards 50. At the conclusion of these operations, the web is finished and may be rolled up for sale or cut into a series of rugs, where the printing operation has produced rug borders.

- Since a final steaming may be employed to dry It will be clear that modifications may be made in my invention without departing from the spirit thereof, and in particular that my process may be carried on on other printing devices than that specifically illustrated herein. The finished web I have illustrated in Fig. 2, where color applications 20 and 2| are shown as extending throughout the body of the fabric, the latex bonding coating being shown at". Anincrease in the intensity of the color shading toward the bottom of the web indicates a concentration of the gum at that point.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent, is:--

1. In a printing apparatus, means for moving a web, means for applying a liquid mordant substance thereto, means for printing upon said web, means for steaming said web, and means for causing said device to act upon said web in timed sequence.

2. In a printing device, means i'or moving a fibrous web, spraying meansifor treating said web with a mordant, printing devices adapted to apply the dye to said web, reciprocating steaming devices adapted'to contact said web under pressure, and means for synchronizing the operations of said devices.

3. In a flat bed writing mechanism, a table means for moving a web along said table, means for applying a mordant initially to said web, reciprocating actuating devices for printing blocks, inking means for said printing blocks, other reciprocating supporting means, and a steaming device attached to said supporting means and arranged to be brought thereby in contact with the web.

4. In a flat bed printing mechanism, a table,

- means for moving a web along said table, means for applying a mordant initially to said web, reciprocating actuating devices for printing blocks, inking means for said printing blocks, other reciprocating supporting means, and a steaming device attached to said supporting means and arranged to be brought thereby in contact with the web, said steaming device comprising a head, a pervious cover arranged to contact said web, resilient means between said Head and said cover, and a steam connection to said head.

5'. In a fiat bed printing mechanism, a table, means for moving a web along said table, means for applying a mordant initially to said web, reciprocating actuating devices for printing blocks, inking means for said printing blocks, other reciprocating supporting means, and a steaming device attached to said supporting means and arranged to be brought thereby in contact with the web, said steaming devices comprising a head,

resiiient means between said head and said cover, a steam connection to said head, and automatic means for controlling the admission of steam to said head in accordance with the movements of said supporting means.

6. In a printing mechanism in combination with printing devices, steaming means comprising a resilientpressing device, a pervious cover therefor adapted to contact a web, steaming connections to said device, and means for bringing said device into pressing relationship with said sheet in synchronism with the printing operations of said printing means.

7. In a printing mechanism in combination with printing devices, steaming means comprising a resilient pressing device, a pervious cover therefor adapted to contact a web, steaming connections to said device, means for bringing said device into pressing relationship with said sheet in synchronism with the printing operations of said printing means, and means for automatically controlling the admission of steam to said steaming device in accordance with said synchronously controlled operations.

8. In a printing mechanism in combination with printing devices, steaming means comprising a resilient pressing device, a pervious cover therefor adapted to contact a web, a steam connection to said device, means for bringing said;

device into pressing relationship with said sheet in synchronism with the printing operations of said printing means, a connection to said'steaming device for fluid means for removing steam from the web, and automatic means for controlling said fiuid means, and the admission of steam to said device, in synchronous relationship to the operations of said printing mechanism. MELVIN R. GREISER. 

